Folded Core Absorbent Article and Related Method

ABSTRACT

A liquid absorbent article includes an absorbent core including a liquid absorbent member and a unitary liquid distribution sheet disposed against a surface of the liquid absorbent member. The liquid absorbent member includes a first absorbent layer surface, a second absorbent layer surface, a third absorbent layer surface in contact with the second absorbent layer surface, and a fourth absorbent layer surface. The unitary liquid distribution sheet includes a first distribution layer surface in contact with the first absorbent layer surface of the liquid absorbent member and a second distribution layer surface in contact with the fourth absorbent layer surface of the liquid absorbent member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority, under 35 U.S.C.§119, to U.S. Patent Application No. 61/904,670, titled ABSORBENTARTICLE WITH WRAP LIQUID DISTRIBUTION LAYER AND RELATED METHODS, filedon Nov. 15, 2013, and U.S. Patent Application No. 61/905,441, titledABSORBENT ARTICLE WITH WRAP LIQUID DISTRIBUTION LAYER AND RELATEDMETHODS, filed on Nov. 18, 2013, each of which is incorporated byreference in its entirety for all purposes.

BACKGROUND

1. Technical Field

The present disclosure generally pertains to absorbent articles such asincontinence care articles, and in particular embodiments, relates toadult briefs, diapers, training pants and youth pants having afluff-free absorbent core with an integrated liquid acquisitiondistribution layer wrapped around a central portion thereof as well asrelated methods thereto.

2. Description of Related Art

Incontinence care articles such as briefs, diapers, youth pants, andtraining pants typically have a first liquid permeable layer disposedproximate or even adjacent a skin surface, an outer impermeable layer,and an absorbent core disposed between the first liquid permeable layerand the outer permeable layer.

The absorbent core can include one or more absorbent materials,including a mixture of superabsorbent polymer particles and fluff pulp.Some products have an embossed core that defines diamond-shaped pocketsincluding a mixture of fluff pulp material and superabsorbent polymerparticles. The embossing process, however, relies on hydrogen bondingphenomena to create the defined embossing lines.

SUMMARY

There is disclosed a liquid absorbent article including an absorbentcore having a liquid absorbent member, which can be a unitary liquidabsorbent member, and a unitary liquid distribution layer, e.g., aunitary liquid distribution sheet, disposed against a surface of theliquid absorbent member. The absorbent core can have an inner sectioncomprised of a first portion of the unitary liquid distribution sheethaving a first distribution layer surface. A first portion of theunitary absorbent member can have a first absorbent layer surface incontact with the first distribution layer surface and a second absorbentlayer surface. A second portion of the unitary absorbent member can havea third absorbent layer surface in contact with the second absorbentlayer surface, and a fourth absorbent layer surface in contact with asecond distribution layer surface. The absorbent core can furtherinclude a front section and a rear section; the inner section istypically disposed between the front and rear sections. In someembodiments, a surface area of the unitary liquid distribution sheet canbe substantially the same as a surface area of the liquid absorbentmember. The absorbent article can further include a liquid impermeableback sheet and a permeable top sheet; the absorbent core can be disposedbetween the top sheet and the back sheet. The liquid absorbent membercan include a layer of superabsorbent particles disposed between tissuelayers. The first absorbent layer surface can be in fluid communicationwith the fourth absorbent layer surface through the unitary liquiddistribution sheet.

There is disclosed a disposable article having a waist opening and apair of leg openings. The disposable article is in the form of a chassiswith a front portion, a back portion, and a crotch portion disposedbetween the back portion and the front portion. A liquid absorbent coreis at least partially disposed in the crotch portion. The liquidabsorbent core includes a unitary liquid distribution sheet disposed ona unitary absorbent member. The liquid absorbent core has an unfoldedsection and a first folded section. The first folded section includes afirst portion of the unitary absorbent member and a first portion of theunitary liquid distribution sheet. The first folded section is disposedon at least a portion of the unfolded section. The liquid absorbent corecan further include a second folded section including a second portionof the unitary absorbent member and a second portion of the unitaryliquid distribution sheet. The second folded section is disposed on atleast a portion of the unfolded section. The unitary liquid distributionsheet can surround the first folded section and the second foldedsection. In cases, a surface area of the unitary liquid distributionsheet can be substantially the same as a surface area of the liquidabsorbent member. The absorbent member can include a layer ofsuperabsorbent particles disposed between layers. The layers include anyone of nonwoven, woven, spunbond, or air-laid fibers. The unitary liquiddistribution sheet can surround the first folded section and the secondfolded section.

There is disclosed a method directed to fabricating an absorbentarticle. The method, in some cases, can include providing a liquidabsorbent member including a layer of superabsorbent particles;disposing a liquid distribution sheet on the liquid absorbent member toproduce a laminate; creating a first partial cut from a first edgetoward a central portion of the laminate; creating a second partial cutfrom the first edge of the laminate to form a first laminate flap;creating a third partial cut from a second edge toward the centralportion of the laminate; creating a fourth partial cut from the secondedge of the laminate to form a second laminate flap; and folding thefirst laminate flap and the second laminate flap onto the centralportion of the laminate to produce the absorbent article. The firstlaminate flap can be a flared flap having a width dimension thatdiminishes from the first edge towards the central portion and thesecond laminate flap can be a flared flap having a width dimension thatdiminishes from the second edge towards the central portion. The firstpartial cut is a linear cut at a first obtuse angle relative to thefirst edge of the laminate. The second partial cut is a linear cut at afirst acute angle relative to the first edge of the laminate. The thirdpartial cut is a linear cut at a second obtuse angle relative to thesecond edge of the laminate. The fourth partial cut is a linear cut at asecond acute angle relative to the second edge of the laminate. Thefirst obtuse angle is substantially equal to the second obtuse angle andthe first acute angle is substantially equal to the second acute angle.Each of the first partial cut, the second partial cut, the third partialcut, and the fourth partial cut can be a curvilinear cut. Respectiveends of the first partial cut and the second partial cut define a firstfold line. Respective ends of the third partial cut and the fourthpartial cut can define a second fold line. Thus, the first laminate flapcan be folded along the first fold line and the second laminate flap canbe folded along the second fold line. The liquid absorbent member canconsist essentially of the layer of superabsorbent particles disposedbetween layers of any one of nonwoven, woven, spunbond, or air-laidfibers. Folding the first laminate flap onto the central portion andfolding the second laminate flap onto the central portion can includebutting an edge of the first laminate flap against an edge of the secondlaminate flap. Folding the first laminate flap onto the central portionand folding the second laminate flap onto the central portion can createa laminated middle portion consisting essentially of the liquidabsorbent material enveloped within the liquid distribution sheet.

DESCRIPTION OF THE DRAWINGS

The features and advantages of the present disclosure will becomeapparent with regard to the following description, claims, andaccompanying figures, wherein:

FIG. 1 is a plan view of an absorbent article having a fluffless, foldedabsorbent core in accordance with one or more aspects of the presentdisclosure;

FIG. 2 is a cross-sectional view of a portion of the absorbent articletaken along the line 2-2 of FIG. 1;

FIG. 3 is a cross-sectional view of the absorbent article taken alongthe line 3-3 of FIG. 1;

FIG. 4 is a plan view illustrating a laminated member that may beutilized to create an absorbent core of the absorbent article inaccordance with one or more embodiments of the present disclosure;

FIG. 5 is a cross-sectional view of the laminated member taken alonglines 4-4 of FIG. 4; and

FIG. 6 is a plan view of an alternate embodiment.

DESCRIPTION

The presently disclosed absorbent articles can include a substrate uponand within which fluid discharge, e.g., liquid insult, may be appliedand absorbed. For illustrative purposes, the absorbent articles inaccordance with the present disclosure will be exemplarily described asa diaper; however, one or more of the features and aspects disclosedherein may be directed or implemented in various liquid absorbentproducts such as feminine hygiene products such as menstrual pads, adultincontinence products such as diapers, youth pants, training pants,adult briefs, protective underwear, pads and bladder control pads, pettraining pads, and other disposable products utilized to absorb fluids.

Absorbent articles can include a multi-layer arrangement with apermeable top sheet for engaging the body surface, a fluid impermeableback sheet for preventing fluid leakage through the article, and anabsorbent core disposed therebetween. One or more aspects of thepresently disclosed articles and related methods involve a preformedabsorbent core. In some particular configurations, the absorbentarticles utilize a preformed, fluff-free or fluffless absorbent core. Inembodiments directed to the diapers, training pants, youth pants,briefs, and incontinence products as well as absorbent pads, theabsorbent article further has a liquid impermeable back sheet and apermeable top sheet, wherein the absorbent core is disposed between thetop sheet and the back sheet.

In an embodiment as exemplarily illustrated in FIG. 1, the absorbentarticle 100 is disclosed in the form of a diaper. The absorbent article100 is generally formable into a chassis having a front waist portion102, a back waist portion 104, and a crotch portion 106 disposed betweenthe front and back waist portions 102, 104. The front waist portion 102and/or the back waist portion 104 may include a pair of fastening tabsor tapes 108 for securing the respective front and back waist portions102, 104 about the user.

With reference to FIGS. 2 and 3, in conjunction with FIG. 1, theabsorbent article 100 further includes a liquid impermeable back sheet110, a permeable top sheet 112, e.g. a liquid permeable top sheet, andan absorbent core 114 disposed between the liquid impermeable back sheet110 and the permeable top sheet 112. The back sheet 100 and the topsheet 112 may or may not be coextensive in size and shape.

The back sheet 110 can be a fluid impervious layer for preventing liquidabsorbed and contained in the absorbent core 114 from wetting articleswhich contact the underpad, such as, but not limited to, undergarments,pants, pajamas, and bed sheets. The back sheet 110 may be: a wovenmaterial; a non-woven material; a liquid-impervious fabric; a cellulosicfilm; a polymeric film such as a thermoplastic film of polyethylene orpolypropylene; an impregnated fluid repellent paper; a compositematerial, e.g., a polylaminate, such as a film-coated non-wovenmaterial; or combinations thereof. The back sheet 110, or at leastportions thereof, may be embossed or may be matte-finished to provide acloth-like appearance, and/or colored for ready identification. The backsheet 110 may also be breathable to allow at least some vapors to escapeor pass from the absorbent core 114, while preventing fluid dischargefrom passing therethrough. Thus, in some cases, the back sheet 100 canbe liquid impermeable but can be a vapor permeable back sheet.

The top sheet 112 can be a woven or nonwoven fabric including polymericfibers. In some cases, the top sheet 112 can be formed of one or morebicomponent polymeric fibers. For example, the top sheet 112 can be afabric with first bicomponent fibers woven with second bicomponentfibers. The top sheet 112 is often a fluid pervious layer for permittingliquid, e.g., menses or urine, to penetrate readily through itsthickness. The top sheet 112 may be compliant and/or soft to the touchso that it does not irritate skin. The top sheet 112 may be manufacturedfrom a wide range of materials such as woven and non-woven materials,e.g., a non-woven web of fibers; polymeric materials such asthermoplastic films having apertures, plastic films having apertures,and hydro-formed thermoplastic films; porous foams; reticulated foams;reticulated thermoplastic films; and thermoplastic scrims. Suitablefibers that may be utilized to construct woven and non-woven materialsinclude, for example, natural fibers, e.g., wood or cotton fibers,synthetic fibers, e.g., polymeric fibers such as polyester,polypropylene, or polyethylene fibers, and combinations of natural andsynthetic fibers.

In embodiments in which the top sheet 112 is a non-woven web, the webmay be spun-bonded, carded, wet-laid, melt-blown, hydro-entangled, orformed using any method suitable for forming a non-woven web. Inaccordance with further embodiments of the disclosure, at least aportion of the liquid pervious top sheet can be formed of a nonwovenfibrous layer of polyolefinic fibers. The fibers can be multicomponentfibers. At least a portion of the fibers of at least a portion of topsheet 112 can include bicomponent fibers having a first component thathas a first fusion point and a second component that has a second fusionpoint that is less than the first fusion point. In accordance with stillfurther aspects of the disclosure, at least a portion of the top sheetcan include thermobondable polymeric bicomponent fibers including ahigh-melting point core and a low melting point sheath substantiallysurrounding the core. The top sheet 120 can include at least about 50%by weight of bicomponent fibers. Thus, for example, the top sheet caninclude monolithic fibers formed of a polyolefin which, in some cases,can be the same polyolefin as the core. In embodiments, however, the topsheet 112 includes bicomponent fibers. In other embodiments, the topsheet 112 consists essentially of bicomponent fibers. In still otherembodiments, top sheet 112 consists of bicomponent fibers.

The top sheet 112 can thus include bicomponent fibers having a core of afirst polyolefin and a sheath around the core of a second polyolefin.The top sheet 112 can also consist essentially of bicomponent fibershaving a core of a first polyolefin and a sheath around the core of asecond polyolefin. In other embodiments, the top sheet 112 consists ofbicomponent fibers having a core of a first polyolefin and a sheatharound the core of a second polyolefin.

In some configurations, the top sheet 112 can include a plurality oflayers. For example, the top sheet 112 can include a first layer, as thebody side layer, including bicomponent fibers and a second layer, distalto the body side layer, including monocomponent fibers. In someconfigurations of the top sheet, the second layer can include spun bondmonocomponent fibers of polyolefin, which may be a polyethylene, and canbe the same polyethylene of the sheath of the bicomponent fibers of thefirst layer. In other embodiments, the top sheet 112 includes a firstlayer, preferably as the body side layer, consisting of or consistingessentially of bicomponent fibers, and a second layer, typically adistal second layer, including or consisting of monocomponent fibers. Insome particular configurations of the top sheet, the second layer canconsist of spun bond monocomponent fibers of polyolefin, in some cases apolyethylene, and can be the same polyethylene of the sheath of thebicomponent fibers of the first layer.

In other embodiments, the first polyolefin can be a polypropylene andthe second polyolefin can be polyethylene. In other configurations, thefirst polyolefin can be a high-density polyethylene and the secondpolyolefin can be low-density polyethylene. For example, the sheath caninclude a linear low-density polyethylene having a density of less thanor about 0.95 g/cm³. The core can include a high-density polyethylenehaving a density of greater than 0.95 g/cm³.

In one embodiment, the back and top sheets 110, 112 are coextensivelengthwise of the article 100, while the width of the top sheet 112 isless than the width of the back sheet 110 in the front and back waistportions 102, 104 of the article. The back and/or top sheets 110, 112may define a pair of side edges 116. Each side edge 116 includes acentral, cutout to define a respective leg cut out. The crotch portion106 is located between the leg cutouts. The back sheet 110 and/or thetop sheet 112 can be any suitable shape and dimensions for other designsor constructions, as will be clear to those skilled in the art.

The back sheet 110 may be bonded to the top sheet 112 around its entireperiphery, with the absorbent core 114 interposed therebetween. The backsheet 110 and top sheet 112 can be joined together in any suitablemanner, e.g., by adhesive bonding. The adhesives can be applied in anymanner such as by spraying, slot-coat extrusion, and printing. Theapplied adhesive can be in any desired configuration or design, such ascontinuous or discontinuous beads, continuous or discontinuous swirls,meltblown patterns, and other predefined patterns. Alternatively, thejoining of layers and structures can be accomplished by heat sealing orby ultrasonic bonding.

Referring still to FIGS. 1-3, the absorbent core 114 of the absorbentarticle 100 will be described. The absorbent core 114 includes at leastone liquid absorbent member 118 and a unitary liquid distribution sheet120 disposed against and/or adhered to a surface of the at least oneliquid absorbent member 118. In certain embodiments, the absorbent core114 is formed as a laminate of the absorbent member 118 and thedistribution sheet 120. In some cases, the absorbent core can consistessentially of the absorbent member 118 and the distribution sheet 120.As depicted in FIG. 1, the absorbent core 114 can have a front section122, a rear section 124, and an inner section 126 disposed between thefront and rear sections 122, 124. The front and rear sections 122, 124of the absorbent member 118 may extend at least partially intorespective front and back waist portions 102, 104 of the absorbentarticle 100. The inner section 126 of the absorbent core 114 may atleast partially encompass the crotch portion 106 of the absorbentarticle 100. In certain embodiments, the absorbent core 114 may bedevoid of the front and rear sections 122, 124, and include only theinner section 126. The front and rear sections 122, 124 of the absorbentcore 114 may include the single laminate with the absorbent member 118superposed relative to the distribution sheet 120 as depicted in thecross-sectional view of FIG. 3.

With reference again to the cross-sectional view of FIG. 2, inconjunction with FIG. 1, the inner section 126 of the absorbent core 114is folded onto itself to provide a multilayer fluid-acquisition unit.The acquisition unit effectively transfers and contains body fluids fromthe subject, and is adapted to accommodate repeated insults of bodyfluids. The details of forming the folded inner section will bedescribed herein below. In one embodiment, the inner section 126 of theabsorbent core 114 is folded such that the liquid distribution sheet 120at least partially or fully encompasses the liquid absorbent member 118.For example, the inner section 126 of the absorbent core 114 c mayinclude first and second folded sections A, B and an unfolded section Cupon which the first and second folded sections A, B are folded. In thismanner, the inner section 126 includes two layers of the absorbentmember 118 surrounded by the liquid distribution sheet 120. The firstand second folded sections A, B may or may not be in juxtaposedrelation.

In the embodiment of FIG. 2, the folded inner section 126 provides afirst portion having a first distribution layer surface 120 a of theliquid distribution sheet 120, a first absorbent layer surface 118 a ofthe absorbent member 118 in contact, e.g., in some cases, in directcontact, with the first distribution layer surface 120 a and a secondabsorbent layer surface 118 b opposing the first absorbent layer surface118 a. The folded inner section 126 also provides a second portionhaving a third absorbent layer surface 118 c of the unfolded section Cin contact, e.g., in some cases, in direct contact, with the secondabsorbent layer surface 118 b, and a fourth opposing absorbent layersurface 118 d in contact, e.g., in some cases, in direct contact, with asecond distribution layer surface 120 b of the unitary liquiddistribution sheet 120. Thus, in some advantageous configurations, thefirst absorbent layer surface 120 a is in fluid communication with thefourth absorbent layer surface 120 d through the unitary liquiddistribution sheet 120.

FIGS. 4-5 illustrate the absorbent core 114 prior to folding or creatingthe folded inner section 126 between the front and rear sections 122,124. In some embodiments, the liquid distribution sheet 120 and theabsorbent member 118 are coextensive, e.g., a surface area of theunitary liquid distribution sheet 120 can be substantially the same as asurface area of the liquid absorbent member 118. As exemplarilyillustrated, the respective contacting surfaces of the liquid absorbentmember 118 and the liquid distribution sheet 120 have substantially thesame surface areas.

The method of formation of the absorbent core followed by a method offabricating an absorbent article, such as, for example, absorbentarticle 100 described above will now be described. With continuedreference to FIGS. 4-5, the method includes disposing the liquiddistribution sheet 120 on the liquid absorbent member 118, whichincludes superabsorbent material, e.g., a layer of superabsorbentparticles, to produce a laminate 130. A first partial cut 132 is createdfrom a first edge 134 of the liquid absorbent core 140, toward a centralportion 136 of the laminate 130. A second partial cut 138 is createdfrom the first edge 134 of the laminate 130 to form a first laminateflap or first folded section A, as mentioned above. A third partial cut140 is created from a second edge 142 of laminate 130 toward the centralportion 136 of the laminate 130. A fourth partial cut 144 is createdfrom the second edge 142 of the laminate 130 to form a second laminateflap or second folded section B, as mentioned above. The first laminateflap A and the second laminate flap B are both folded, in the directionindicated by arrows D and E in FIG. 5, and as depicted in phantom ontothe central portion 136 of the laminate 130 to produce the absorbentcore 114 shown in FIGS. 1 and 2.

The first laminate flap A can be a flared flap having a width dimensionthat diminishes from the first edge 134 towards the central portion 136and the second laminate flap B can be a flared flap having a widthdimension that diminishes from the second edge 142 towards the centralportion 136.

The respective ends of the first partial cut 132 and the second partialcut 138 can define a first fold line 146 (FIG. 4) and respective ends ofthe third partial cut 140 and the fourth partial cut 144 can define asecond fold line 148 (FIG. 4). Thus, the first laminate flap A can befolded along the first fold line 146 and the second laminate flap B canbe folded along the second fold line 148 to create the liquid absorbentcore 114. The fold lines 146, 148 may be perforated, cut or scored, oralternatively, devoid of any cuts. Thus, in some cases, folding thefirst laminate flap A and the second laminate flap B onto the centralportion 136 can involve butting an edge of the first laminate flap Aagainst an edge of the second laminate flap B.

The first partial cut 132 can be a linear cut at a first obtuse angle αrelative to the first edge 134 of the laminate 130. The second partialcut 138 can be a linear cut at a first acute angle β relative to thefirst edge 134 of the laminate 130. The third partial cut 140 can be alinear cut at a second obtuse γ angle relative to the second edge 142 ofthe laminate 130. The fourth partial cut 144 can be a linear cut at asecond acute angle δ relative to the second edge 142 of the laminate130. In some embodiments, for example, as illustrated in FIG. 4, thefirst obtuse angle α is substantially equal to the second obtuse angleα′ and the first acute angle β can be substantially equal to the secondacute angle β′.

Each of the first partial cut 132, the second partial cut 138, the thirdpartial cut 140, and the fourth partial cut 144 may be a linear cut, asexemplarily illustrated in FIG. 4, or any one or more of such partialcuts 132, 138, 140, 144 can be a non-linear or curvilinear cut, asdepicted in FIG. 6.

In some advantageous configurations, the liquid absorbent memberconsists essentially of the layer of superabsorbent particles disposedbetween layers. The layers between which the superabsorbent particlesare disposed can include any one of nonwoven, woven, spunbond, orair-laid fibers. Suitable materials for use as the super absorbentpolymer particles include starch type, starch-graft polymers,cellulosic, and synthetic types, starch-acrylic acid (salt) graftcopolymers, saponified starch-acrylonitrile copolymers, cross-linkedsodium carboxymethyl cellulose, acrylic acid (salt) polymers,cross-linked polyacrylate polymers, polyacrylamides, polyethyleneoxides, polyvinyl alcohols, polysuccinimides, hydrolyzedpolyacrylonitriles, combinations thereof. As a shape for the superabsorbent polymer particles, powder-particle may be desirable, but othershapes can be also used.

In some advantageous configurations, folding the first laminate flap Aand the second laminate flap B onto the central portion 136 provides alaminated middle portion consisting essentially of the liquid absorbentmember 118 enveloped within the liquid distribution sheet 120. Thus, insome cases, the absorbent media can be spread over a larger area,resulting in an absorbent incontinence article that is thinner and morecomfortable to the user while providing protection in crotch area,instead of using a thick core strip limited by crotch width and furtherreduces waste material by cutting out the leg opening from the crotcharea.

A sample was made by cutting a core out of a GELOK® 11040-72-S/Sabsorbent material. This absorbent material contained superabsorbentpolymer at 110 gsm basis weight with 12 tissues. The absorbent materialwas cut to be 14 inch wide and 24 inch length for 335 in², at 48 gram.An 11 inch long by 14 inch wide piece of 15 gsm hydrophilic spunbondliquid acquisition distribution sheet (from Polymer Group, Inc.) wasattached to one side at approximately 7 inch from one end andapproximately 6 inch from the other end of the GELOK® material toproduce a laminate. Diagonal cuts were made at about 11 inch from a backend and at about 6 inch from a front end to form flaps. The flaps werefolded over to meet in the middle to make an absorbent core with a 7inch wide crotch area. The absorbent core was attached to polyfilm withthe crotch area centered along the elasticized leg openings thereof anda top sheet was attached thereto. This brief weighed about 73 grams witha core having a thickness (at the crotch) of about 0.90 inch and about0.040 inch at the remainder. The absorbency capacity is expected to beabout 1800 grams of saline.

Having described the present disclosure in detail, it will be apparentthat modifications and variations are possible without departing fromthe scope of the present disclosure defined in the appended claims. Forexample, different types of superabsorbent material can be used totailor the performance characteristics of the absorbent core or theabsorbent article, at various relative amounts and at various regions ofthe core or the absorbent article.

When introducing elements of the present disclosure or theembodiments(s) thereof, the articles “a,” “an,” “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising,” “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. While the above description refers to many devices, methods,and/or elements as including or having certain features and/orcomponents, it is to be understood that disclosure also encompassesdevices, methods, and/or elements “consisting essentially of” or“consisting of” those features and/or components.

Thus, the transitional phrase “consisting of” excludes any element,step, or ingredient not specified in the claim, closing the claim to theinclusion of materials other than those recited except for impuritiesordinarily associated therewith. When the phrase “consists of” appearsin a clause of the body of a claim, rather than immediately followingthe preamble, it limits only the element set forth in that clause; otherelements are not excluded from the claim as a whole.

The transitional phrase “consisting essentially of” limits the scope ofa claim to the specified materials or steps and those that do notmaterially affect the basic and novel characteristics of the claimedinvention. A “consisting essentially of” claim occupies a middle groundbetween closed claims that are written in a “consisting of” format andfully open claims that are drafted in a “comprising” format.

While the above description contains many specifics, these specificsshould not be construed as limitations on the scope of the presentdisclosure, but merely as exemplifications of embodiments thereof. It isenvisioned that the elements and features illustrated or described inconnection with one exemplary embodiment may be combined with theelements and features of another exemplary embodiment without departingfrom the scope of the present disclosure, and that such modificationsand variations are also intended to be included within the scope of thepresent disclosure. Those skilled in the art will envision many otherpossible variations that are within the scope and spirit of the presentdisclosure.

1-19. (canceled)
 20. A liquid absorbent article comprising an absorbent core comprising a liquid absorbent member and a unitary liquid distribution sheet disposed against a surface of the liquid absorbent member, wherein the absorbent core has an inner section comprised of a first portion of the unitary liquid distribution sheet having a first distribution layer surface, a first portion of the unitary absorbent member having a first absorbent layer surface in contact with the first distribution layer surface and a second absorbent layer surface, a second portion of the unitary absorbent member having a third absorbent layer surface in contact with the second absorbent layer surface, and a fourth absorbent layer surface in contact with a second distribution layer surface.
 21. The article as set forth in claim 20, wherein the absorbent core further includes a front section, a rear section, and wherein the inner section is disposed between the front and rear sections.
 22. The article as set forth in claim 21, wherein a surface area of the unitary liquid distribution sheet is substantially the same as a surface area of the liquid absorbent member.
 23. The article as set forth in claim 22, further comprising a liquid impermeable back sheet and a permeable top sheet, wherein the absorbent core is disposed between the top sheet and the back sheet.
 24. The article as set forth in claim 23, wherein the liquid absorbent member includes a layer of superabsorbent particles disposed between tissue layers.
 25. The article as set forth in claim 24, wherein the first absorbent layer surface is in fluid communication with the fourth absorbent layer surface through the unitary liquid distribution sheet.
 26. A disposable article having a waist opening and a pair of leg openings, comprising a chassis with a front portion, a back portion, and a crotch portion between the back portion and the front portion, and a liquid absorbent core at least partially disposed in the crotch portion, and comprising a unitary liquid distribution sheet on a unitary absorbent member, the liquid absorbent core having an unfolded section and a first folded section comprising a first portion of the unitary absorbent member and a first portion of the unitary liquid distribution sheet, wherein the first folded section is disposed on at least a portion of the unfolded section.
 27. The disposable article as set forth in claim 26, wherein the liquid absorbent core further includes a second folded section including a second portion of the unitary absorbent member and a second portion of the unitary liquid distribution sheet, wherein the second folded section is disposed on at least a portion of the unfolded section.
 28. The disposable article as set forth in claim 27, wherein a surface area of the unitary liquid distribution sheet is substantially the same as a surface area of the liquid absorbent member.
 29. The disposable article as set forth in claim 28, wherein the absorbent member includes a layer of superabsorbent particles disposed between layers, wherein the layers include any one of nonwoven, woven, spunbond, or air-laid fibers.
 30. The disposable article as set forth in claim 29, wherein the unitary liquid distribution sheet surrounds the first folded section and the second folded section.
 31. A method of fabricating an absorbent article comprising: providing a liquid absorbent member including a layer of superabsorbent particles; disposing a liquid distribution sheet on the liquid absorbent member to produce a laminate; creating a first partial cut from a first edge toward a central portion of the laminate; creating a second partial cut from the first edge of the laminate to form a first laminate flap; creating a third partial cut from a second edge toward the central portion of the laminate; creating a fourth partial cut from the second edge of the laminate to form a second laminate flap; and folding the first laminate flap and the second laminate flap onto the central portion of the laminate to produce an absorbent core of the absorbent article.
 32. The method as set forth in claim 31, wherein the first laminate flap is a flared flap having a width dimension that diminishes from the first edge towards the central portion, and wherein the second laminate flap is a flared flap having a width dimension that diminishes from the second edge towards the central portion.
 33. The method as set forth in claim 31, wherein the first partial cut is a linear cut at a first obtuse angle relative to the first edge of the laminate, the second partial cut is a linear cut at a first acute angle relative to the first edge of the laminate, the third partial cut is a linear cut at a second obtuse angle relative to the second edge of the laminate, the fourth partial cut is a linear cut at a second acute angle relative to the second edge of the laminate, and wherein the first obtuse angle is substantially equal to the second obtuse angle and the first acute angle is substantially equal to the second acute angle.
 34. The method as set forth in claim 31, wherein each of the first partial cut, the second partial cut, the third partial cut, and the fourth partial cut is a curvilinear cut.
 35. The method as set forth in claim 34, wherein respective ends of the first and second partial cuts define a first fold line and respective ends of the third and fourth partial cuts define a second fold line, and wherein the first laminate flap is folded along the first fold line and the second laminate flap is folded along the second fold line.
 36. The method as set forth in claim 35, wherein the liquid absorbent member consists essentially of the layer of superabsorbent particles disposed between layers of any one of nonwoven, woven, spunbond, or air-laid fibers.
 37. The method as set forth in claim 36, wherein folding the first laminate flap and the second laminate flap onto the central portion includes butting an edge of the first laminate flap against an edge of the second laminate flap.
 38. The method as set forth in claim 36, wherein folding the first laminate flap and the second laminate flap onto the central portion provides a laminated middle portion consisting essentially of the liquid absorbent member enveloped within the liquid distribution sheet. 